1999-2020 Ford F250/350 Standard Headache Rack Kit


What’s Included:

  1. Easy-to-Use Blueprint – downloadable upon purchase. See below to preview blueprints.
  2. Machine Made Gussets & Light brackets shipped to you – delivered 5-10 business days after purchase. See photo 2a. and 2b. This kit DOES NOT include all the parts you need, only the machine made gussets and light brackets. You will have to purchase additional steel that is laid out clearly in the blueprint that is included. Scroll down for details and frequently asked questions. 
  3. Video Tutorial Access – this kit is designed to be built using our start to finish video tutorial.

If you have a cross body toolbox, select “Toolbox” in the drop down menu below. The toolbox gusset accommodates for a 73.75” wide toolbox. If you don’t have a cross body toolbox, choose “Regular” in the drop down menu below. See product photos for examples of each style.

Adding marker lights and/or strip tail/stop/turn lights are optional. Product links to purchase these items are located under the video pane on the video tutorial page.

If you would rather purchase .dxf cut files instead of physical parts, click here.

SKU: ford-premium-headache-rack-kit Categories: ,
Double Diamond Headache Rack Kits

What Experience and Tools are Required to Build My Kit?

Equipment Required:

  • Standard Protective Equipment (Ear Plugs, Safety glasses, Welding Helmet, Welding Gloves, Welding Coat)
  • Work Table
  • Welder – capable of welding 3/16” plate
  • Bandsaw capable of cutting 2.5” square tubing (If you don’t have a bandsaw, you can get your pieces cut at a local welding shop)
  • Angle Grinder
  • Tape Measure
  • Vice grips OR C-clamps – at least two, four preferred
  • Square
  • Hand Drill OR Drill Press
  • ¼” Drill Bit
  • ¾” Drill Bit (only needed if adding marker lights)
  • Type 27 Flapper Disk Grinding Wheels
  • Grinder Cutting Wheel OR Plasma Cutter OR Cutting Torch

Experienced Required:

  • Beginning to Intermediate Welding Experience
  • General Knowledge of using a bandsaw (includes cutting angles) If you don’t have a bandsaw, you can get all your pieces cut at a local welding shop.
  • General Shop Tool Knowledge (how to use hand drill, grinder, etc.)

No Experience or Tools? No Problem. Give your local welding shop a copy of the blueprint and video access and they will easily be able to complete the project.

What's Included

1) Easy-to-Use Blueprints

These aren’t the jargon-filled standard blueprints, they’re made for everyone to understand. Blueprints Include a detailed material list and diagrams of lengths and angles to cut all pieces.

What's Included

2) Custom Machine Made Parts

We ship you machine made gussets and light brackets to set your rack apart.

Preview Our Double Diamond Kit Video Course

Full Access to Our Video Course is Included with Your DIY Headache Rack Kit

Cutting your Light Holes [Preview] 0:45

Tack Welding Outer Frame [Preview] 0:56

Adding your Light Brackets [Preview] 1:01

Preview Our Double Diamond Kit Blueprints

Frequently Asked Questions

Why does this only include machine made parts, not all the parts?

The goal of this product is to make it as affordable as possible for the customer (you). That being said, we would rather give you a blueprint that is easy to follow so you can cut out the majority of the parts instead of charging you for the cost, markup, and shipping to build and send all the parts to you. We do send you the machine made gussets and light brackets for the professional touch.

This course is easy to follow, but what if I have a question? Will there be support available?

Absolutely. We make sure every customer is able to fully complete their rack. All purchasers will have full access to email and phone support (with a real human) ensuring any and all questions are answered.

How much is this going to cost to build the finished product, all things considered?

DIY Double Diamond Kit – $99 – $109

*Steel you will need to purchase – $90-$110

*Finish (Paint/Powder Coat) – $10 – $150 

Total: $199 – $369

Add Marker Lights & wiring (6): +$35

Add Strip Tail/Stop/Turn Lights & wiring: +$35

Compare to Protech Premade Rack: MSRP $475-$750

Compare to Highway Products Premade Rack: MSRP $599+

*Price subject to your area’s steel retailer and powder coat supplier*

Does this product fit with a cross body toolbox?

Yes. Simply choose the toolbox option at checkout for a specialty gusset to fit with most cross body tool boxes. The maximum overall outer width of the toolbox that can be accommodated will be based on your pickup model. This rack can accommodate a 73.75″ outer width when using the toolbox gusset. 

How long will it take to build?

An experienced fabricator can get this project done in 6 hours, whereas a beginner might need a full day.

Weld-it-Yourself Headache Rack Kits

Every kit includes easy-to-follow blueprints, machine made parts shipped to your door, and full access to our step-by-step video course.

Additional information

Gusset Type

Regular, Toolbox


There are no reviews yet.

Be the first to review “1999-2020 Ford F250/350 Standard Headache Rack Kit”

Your email address will not be published. Required fields are marked *